Professional Documents
Culture Documents
Section 1: General
A. Johnston Contact Information
B. Introduction
C. The Boiler
D. The Burner
E. About Drawings
F. Warranty General Information
G. Parts and Service Policy
H. Warranty Claims
J. Boiler /Burner Model Key
Section 2: Components
A. General Trim Overview
B. Fig 2.1 Steam Boiler Trim
C. Fig 2.2 Water Boiler Trim
Section 5: Engineering
A. Glossary of Terms
B. Formulas and Conversions
C. Combustion
D. Scale Deposits
Note 1:
Section 3: Installation
A. General Information
B. Installation Readiness
C. Boiler Room Air Supply
D. Stack Design and Operation
E. Boiler Boil-out Procedure
F. Recommended Water Quality
Section 4: Maintenance
A. General
B. Part-Specific
C. Maintenance Schedule
D. Idle Boiler Lay-Up
General
Wet Method
Dry Method
Operation
Startup, Adjustments, Shutdown and trouble
shooting will be found in the Burner portion of
the manual. (If applicable)
Section 1: General
A: Contact Information
Pat Baker
Phone 616-638-4737
Fax
616-842-1854
Email pbaker@johnstonboiler.com
Thom Parker
Phone 616-842-5050 ext 314
Fax
616-842-1854
Email tparker@johnstonboiler.com
Deaerators (ancillary)
Rick Slater
Phone 616-842-5050 ext 336
Fax
616-842-1854
Email rslater@johnstonboiler.com
SERVICE
Technical Support
Or Field Service
Ed Wessel
Phone 616-842-5050 ext 311
Fax
616-846-6380
Email ewessel@johnstonboiler.com
or service@johnstonboiler.com
Spare or Replacement
Donna Utzman
Phone 616-842-5050 ext 317
Fax
616-846-6380
Email dutzman@johnstonboiler.com
PARTS
Section 1:
B. Introduction
Thank you for purchasing a series PFT Boiler from Johnston Boiler Company.
All Johnston Boiler products are designed and manufactured to give excellent, efficient performance over
a long period of time. All items supplied were chosen because of their ability to give high quality
performance. Proper operating and maintenance procedures must be followed at all times to ensure a
high degree of protection and safety. Operation of this equipment should not be considered free from all
dangers inherent to operating a steam/hot water vessel with the firing of a combustible fuel.
The operator is solely responsible for properly maintaining the equipment. No amount of documented
instruction can take the place of intelligent thinking and consistent safe practices. This manual is not
intended to relieve the operator of the responsibility of proper operation.
The operator must be familiar with all components and operations of the level, pressure and temperature
controls as well as the fuel burning equipment. Identify and locate each component of your system.
Section 1:
F. Warranty General Information
Products manufactured by the Company are warranted to be free from defects in material and
workmanship under normal use and service for a period of one (1) year from start-up but not to
exceed eighteen (18) months from shipment or completion of manufacture. Components which
are purchased by the Company and resold without further processing by the Company are not
covered by the Companys warranty, but the Company shall pass on to the Buyer whatever
warranty the Company receives from the manufacturer of such products. Components which are
supplied by the Company but field installed by others are not covered unless installation has been
inspected and accepted by an authorized Johnston Representative. The Company will repair or
replace, at its option, its products which prove to be defective within the warranty period F.O.B.
Companys factory. The Companys warranty shall be voided by any repair, alteration or
modification by persons other than the Employees of the Company or those expressly authorized
by the Company to make repairs, or by any abuse, misuse or neglect of the products or by use
not in accordance with the Companys published instructions. The remedies for any failure of the
Companys products to meet its warranty specified herein shall be those remedies as a condition
of sales irrespective of the theory upon which any claim might be based, including negligence,
breach of contract, or strict liability. THIS PARAGRAPH CONTAINS THE COMPANYS SOLE
WARRANTY. THE COMPANY MAKES NO IMPLIED WARRANTY AND THERE IS NO IMPLIED
WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE.
NOTE:
NOTE:
It is the responsibility of the individual, company, organization, or institution receiving a new
boiler, or packaged system to inspect the shipment for damage, alteration or missing components
upon initial receipt. Transporters insist that all deficiencies be noted on the shipping
documentation prior to acceptance. Johnston will not accept responsibility for shipping damages
or claims against transporters.
NOTE:
Each Johnston Boiler is shipped with an order specification sheet, bill of materials, piping
diagram, wiring diagram, and other reference materials specific to this job. A thorough
understanding of and familiarity with these documents is required prior to systems installation,
commissioning, operation or trouble shooting.
.
Section 1:
G. Parts and Service Policy
Johnston Boiler Company markets their products through a distribution system, made up of independent
manufacturers representatives. For parts and service requirements, contact your authorized Johnston
representative.
H. Warranty Claims and Material Return
Johnston Boiler Companys warranty on parts, whether purchased as a component part of a new boiler or
as a replacement part, is as described under the WARRANTY AND EXCLUSION OF IMPLIED
WARRANTIES paragraph of Johnstons Standard Terms and Conditions of Sale. Johnstons parts
warranty claim policy and return procedure is as follows:
It is recognized that often a warranty replacement part may be needed in advance of returning the
claimed defective part for warranty consideration. Johnston Boiler Company can accommodate this
situation. In order for Johnston to advance a warranty replacement part, a written purchase order must
be issued to Johnston Boiler Company in the amount of the selling price for the replacement part and to
cover any prepaid shipping charges that Johnston may incur. Upon receipt of the purchase order, and
subject to availability of the replacement part, the advance warranty replacement part will then be shipped
in the manner requested. At this same time, Johnston will issue and submit an invoice covering the part
and freight charge.
Johnston will include a pre-numbered, 3-part Return Authorization Tag (Exhibit A) with the shipment of an
advance warranty replacement part. This tag must be completed by someone knowledgeable of the
claimed defect in the part to be returned. The green copy of the tag, which reads "TO BE RETAINED BY
PARTY MAKING RETURN, is to be kept by the party making the return. The remaining two (2) copies of
the tag yellow JBC RECEIVING GIVE TO JBC SERVICE/PARTS and buff (hard copy) ATTACH TO
PART BEING RETURNED (ALSO TO INCLUDE YELLOW COPY): are to be attached to the claimed
defective part. The part is then to be returned to Johnston Boiler Company, freight prepaid (collect freight
shipments will not be accepted), for warranty consideration.
Upon Johnstons receipt of the claimed defective part, the part will be reviewed for warranty
consideration. A decision to accept or reject the warranty claim will be made. On parts that were
manufactured by Johnston, this decision will be made by Johnston. On parts that were purchased by
Johnston, the claimed defective part will be returned by Johnston to the actual manufacturer of the part,
to be reviewed for warranty consideration. Any such other manufacturer will make the decision to accept
or reject the warranty claim. Johnston will forward this decision on to its customer, the same as with
Johnstons own decision on warranty claims covering any parts it manufactures. Johnston will notify its
customer of the decision regarding a parts warranty claim in writing.
On accepted parts warranty claims, Johnston Boiler Company will then cancel its invoice covering
shipment of the advance warranty replacement part, less any prepaid shipping charges. Any prepaid
shipping charges are due and payable by a customer, in accordance with the terms of Johnston Boiler
Companys warranty.
On rejected parts warranty claims, Johnston will include in its written notification to a customer, the
reason why the warranty claim was rejected. On rejected parts warranty claims, Johnstons invoice
covering the warranty replacement part, whether advanced or otherwise is due and payable in the full
amount by the customer.
All claimed defective parts must be returned to Johnston Boiler Company for warranty consideration no
later than thirty (30) days after the advance warranty replacement part was shipped by Johnston.
On non-warranty claim parts returns, authorization to make any such return must be received from
Johnston prior to making the actual return shipment. Johnston will mail to the customer the prenumbered, 3-part Return Authorization Tag. (Exhibit A) This tag is then to be completed and handled in
the same manner as a warranty claim.
Section 1:
EHXIBIT A
Return
Freight
Prepaid To:
) Credit
) Warranty Replacement
Section 1:
J. Model Description Key
The Johnston boiler is a steam or hot water packaged firetube boiler, ranging in size from 50 to
2,500 horsepower, 15# to 350# design pressure, 3 or 4 pass, of welded steel construction with
submerged rear combustion chamber. The package consists of a pressure vessel, base frame,
forced draft burner, fuel train(s), control panel, power panel and miscellaneous boiler trim.
Your Johnston boiler will be assigned a model number made up of the following:
PFT
1
A
2
600
3
4
4
LG
5
150
6
S
7
1.
PFT, PFX
2.
Type of Burner
A
J
I
JO
AO
X
P
G
W
S
3.
Horsepower
50 through 3,000
4.
Number of passes
2, 3 or 4
5.
Fuels
H
M
L
G
DG
P
X
6.
Design Pressure
15 to 350
7.
Type of Boiler
S
W
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
Johnston A Burner
Johnston J Burner
Industrial Combustion Burner
Ohio Special with J style burner
Ohio Special with A style burner
No burner
Power Flame burner
Gordon Piatt burner
Webster burner
Johnston S burner
Heavy oil
Medium oil
Light oil
Natural gas
Digester gas
Propane or Propane-Air mix
Special or no burner supplied at factory
Steam
Hot Water
Section 2: Components
A. Component Overview General Trim Items Fig 2.1, Fig 2.2
Johnston Series PFT Boilers generally include the following trim items. Where the word steam is
indicated, the device commonly applies to steam boilers only.
Safety Relief
valve(s)
Feedwater
modulating
control valve
(steam)
Low Water
Cutoff
Optional:
Boiler Level
Controller
(steam)
Operating Limit
Controller
High Limit
Control
Slow opening
blowoff valve
Continuous
Position indicating hand wheel
blowoff control needle valve to meter the
valve (steam) discharge of condensate at the
top of the boiler.
Continuous
blowoff
control valve
(steam)
Modulating
Signals burner to adjust firing
press or temp. rate on the basis of the boilers
controller
current
operating
pressure/temperature.
Automatic
continuous
blowoff
system
(steam)
Pressure or
combination
press altitude
gauge
Steam stop
Stop gate valve to isolate boiler.
valve (steam)
Sight glass
Tri-cocks
When
opened,
gives
indication of water level.
secondary
Section 2:
Steam Boiler Trim
FIGURE 2.1
Section 2:
FIGURE 2.2
Section 3: Installation
A. General
The following are general recommendations for installing a Johnston Packaged Boiler. Project
plans and state and local code requirements must also be followed. These legal
requirements take precedence over information found in this manual.
B. Installation Recommendations
The boiler should be set on a raised concrete pad. The boiler should be level and its base frame
should be grouted to the raised concrete pad. A 36 aisle space at the sides and to the rear of
the boiler is recommended. Adequate space for boiler tube removal and replacement should be
provided to the front of the boiler. Refer to the specified boiler size requirements, in this regard.
The flue gas outlet connection on a Johnston Boiler is only intended to support a limited boiler
stack, or breeching. The minimum stack diameter for a given size boiler should be adhered to.
Section 3:
Where a breeching is used, a round breeching is preferred. If a rectangular breeching is used,
stiffeners should be provided in large flat areas of the breeching, not only for strength, but to
minimize the possible vibration and noise that may be experienced from using a rectangular
breeching.
If two or more boilers are installed in a common breeching, the breeching size should get
progressively larger from the boiler farthest from the stack to the boiler nearest the stack. This is
done to accommodate the additional volume of flue gas from one boiler to the next.
A rain cap is recommended on a stack connected directly to the boiler. The rain cap should be
mounted no less than the diameter of the stack, and above the end of the stack.
Boiler feed, steam or water, fuel piping and electrical supply lines should be properly installed to
the boiler. It is recommended that feedwater and fuel supply lines be properly valved, so the
supply lines to the boiler can be shut off when it is not in use or when preventive maintenance or
repairs to the boiler are being made. A dirt trap should be installed in the gas supply line, just
prior to entering the main gas train of the boiler. A means to disconnect and lockout the power
supply to the boiler control panel should also be provided. Installation of boiler feedwater, fuel
and electrical power supply piping and lines should be checked, so as not to interfere with
operation of any component part of the boiler, or interfere with the ability to perform preventive
maintenance or make repair. Special attention should be given to making sure that no piping or
lines interfere with the boiler fluebox doors.
Warning
Very often boiler safety relief valves are
removed from the boiler, following factory
testing of the boiler, just prior to shipment.
These safety relief valves must be
properly reinstalled on the boiler, using
only a safety valve wrench. Using a
conventional wrench often damages safety
relief valves. This type of damage is not
covered under the boiler warranty. All
safety relief valves should be piped to a
safe point of discharge. Safety relief valve
discharge piping should have an internal
area equal to or greater than the internal
area of the valve outlet. The discharge
piping should be arranged and installed so
that no strain is imposed on the safety
relief valve
Warning
All blowoff and blowdown valves, including
any Johnston supplied piping, whether water
column, surface/continuous or bottom,
should be piped, or further piped, properly
and to a safe point of discharge. If they are
piped into a blowdown separator, the
blowdown line should be properly valved, so
the boiler is capable of being completely
drained.
Section 3:
How much air is required?
In general, the following formulas have been developed to determine the amount of combustion
air required for any boiler room with a package firetube boiler firing gas or oil fuels:
ft 3
min HP
ft 3
Ventilation _ Air = HP 2
min HP
ft 3
Total _ Air _ Re' q = HP 10
min HP
Combustion _ Air = HP 8
For any
Air Ducting
In some applications, the boiler room is located in a building such that it has no outside walls.
Many of these applications do not have sufficient excess makeup air in the factory to allow for
combustion air requirements. In these cases, there are two possible solutions:
Section 3:
1. Ducting fresh air into the boiler room. Where this is required, the general rules for the size of
the wall opening can be used to determine the size of the ducting and wall opening in the
boiler room. In addition, the pressure drop through the duct must never exceed 0.05 w.c.
2. Ducting fresh air directly into the boiler. This method of air supply should be avoided
whenever possible. The disadvantages of this type of system far exceed any perceived
advantages. If used, the ducting becomes a part of the boiler system and can affect the
stability of combustion due to varying weather conditions, wind direction and velocity,
humidity, and temperature. Changes in temperature can lead to massive CO production,
soot formation, and unstable, unsafe combustion.
If direct ducting is to be used, we suggest the following steps be followed:
1. Each boiler has its own, completely separate, fresh air ducting and exhaust stack to minimize
combustion problems.
2. Boiler directly connected to fresh outside air ducts must be checked for proper combustion
adjustment and operation every three months by a certified package firetube boiler specialist.
3. The duct work supplying the fresh air to the boiler must be sized so that it has a maximum
pressure drop of 0.05 w.c. at maximum flow.
4. The fresh air supply should have an electric, hot water, or steam heater to temper cold outside
air to at least 50 deg F.
5. If the application is utilizing a low emission with flue gas recirculation, do not use direct ducted
outside air. The potential problems associated with a standard burner are intensified with a
low emission burner.
Section 3:
A very high stack that does not have some type of insulation, in addition to the problem listed
above, can have widely ranging draft conditions caused by changes in the ambient air
temperature. Cool ambient temperatures can chill flue gas products and reduce or eliminate draft
conditions that existed with warmer ambient air. These conditions can change from winter to
summer, day to night, and sometimes day to day.
Stack Exit Location A stack exit that is located in an area where it is subject to very high and
varying winds can create operational problems that appear to have no logical explanation. These
problems are more difficult to find if the high and varying winds are created or amplified by the
buildings located at the site.
Breeching When required, the breeching should be as short as possible. They should be
constructed of round ducts only. Round ducts are more efficient, and the large flat sides of
square or rectangular ducts contribute to noise caused by resonance. The breeching must be
installed with a slight upward pitch toward the stack to ensure it is self-venting.
Breeching Turns From turns as small as 30o up to 90o, the design of the turn can have a major
effect on the boilers operation. Never use an abrupt turn. Changes in direction should be
accomplished as gradually as possible. Mitered elbows should be avoided. Circular elbows
should be of a minimum of four piece construction and have a minimum R/D ratio of 2.0 where R
is the centerline radius of the arc and D is the diameter of the duct. (Source: Packaged Firetube
Boiler Engineering Manual, American Boiler Manufacturers Association, First Edition, page
35)
Poorly designed turns in an exhaust system can develop reflective harmonics, or noise, that can
upset or destroy stable combustion. These disturbances may not be seen at startup, but develop
later as the exhaust system warms up.
Multiple Boiler Stack A common type of installation is two or more boilers using a common
exhaust system. With such a system, it is absolutely essential that the two boilers be isolated
from each other. The most common method to achieve separation is the use of sequencing draft
controls. Even with their installation, a detailed review of the system is required to ensure
trouble-free operation.
Multiple breeching connections must never enter the stack at the same height. The flow of
exhaust gases into each other can create excessive turbulence that results in combustion stability
problems of flue gases being vented back into the boiler room.
Section 3:
TOTAL BOILER
HORSEPOWER
DIAMETER OF
BREECHING REQUIRED
50
08"
60
10"
75
12"
90
12"
180
16"
250
18"
400
20"
450
22"
600
24"
700-750
25"
800-900
28"
1000
30"
1250
32"
1500
34"
1800
36"
2400
40"
Breeching to Stack Connections The breeching connection to the stack should always be
made with a 45o upward sweeping elbow or mitered turn. A straight in 90o connection, or
bullhead type connection, is almost guaranteed to create reflective harmonics or other problems
that appear to be combustion problems.
Stack Size Pressure drops through the boiler exhaust system should be calculated and in
general should not exceed 0.2 WC. Undersized stacks create excess back pressure on the
boiler resulting in combustion problems, inability to make full capacity, or both.
There are several very competent manufacturers of boiler exhaust systems. They should
be contacted and asked to review your exhaust system whenever there are any
complications beyond a simple, short, straight stack. A little extra time and a few extra
dollars will pay off in a smoother and quicker startup followed by years of successful
operation.
Section 3:
E. Boiler Boil-out Procedure
It is recommended that your new Johnston Boiler be boiled-out before placing it into service. This
may be done before or immediately following initial start-up. A proper boil-out will remove any
grease or oil that may still be present in the waterside of the boiler as the result of boiler
installation. A clean boiler waterside is one of the requirements of establishing and maintaining a
stable waterside condition.
JOHNSTON BOILER COMPANY DOES NOT BOIL-OUT THE BOILER.
IT IS
RECOMMENDED THAT A QUALIFIED WATER TREATMENT CONSULTANT IN YOUR AREA
BE CONTACTED FOR A RECOMMENDATION ON A BOIL-OUT COMPOUND, WHICH
SHOULD INCLUDE ITS OWN USE PROCEDURE. IN THE ABSENCE OF A BOIL-OUT
PROCEDURE, JOHNSTON BOILER RECOMMENDS THE FOLLOWING:
1. Isolate boiler from piping system (valve off).
2. Remove safety valves from the boiler. A boiler safety valve tapping on the top of the boiler
pressure vessel is often used as the opening to introduce the boil-out compound into the boiler.
It will also serve as a vent to fill the boiler and operate it during boil-out.
WARNING:
ONLY QUALIFIED AND EXPERIENCED PERSONNEL SHOULD PERFORM A BOILER BOILOUT. STEPS MUST BE TAKEN TO BE PROPERLY PROTECTED AGAINST THE HAZARDS
OF HANDLING AND USING BOIL-OUT COMPOUNDS.
3. Fill the boiler with clean, ambient temperature water. Allow sufficient room for the boil-out
compound solution (generally diluted) and expansion of the water. The boiler will be boiled
out to atmosphere.
4. Start the boiler, following the appropriate start-up procedure included in this Manual. The
boiler will be operated in the manual mode, low fire setting, for the duration of the boil-out.
Observe the open safety valve tapping, as the boiler is being warmed. Due to expansion,
water will have to be drained from the boiler to prevent it from overflowing. Any number of
blowdown valves can be used to drain the boiler during boil-out; however, follow the boil-out
compound suppliers instructions on how to dispose the chemically treated boiler water. You
might not be permitted use of a normal floor drain by environmental regulations.
5.
Continue to observe the open safety valve tapping on the top of the boiler. As the boiler
water begins to boil, and then develop into a steady discharge of steam coming out of the
open safety valve tapping, turn the boiler off. Wait until the steady stream of steam reduces
to only traces of radiant steam, and then restart the boiler. Repeat this process as often as
necessary for the duration of the boil-out.
6. After the boiler has been allowed to cool down to normal hot water temperatures, drain the
boiler completely. Follow the boil-out compound suppliers instructions on how to dispose of
the chemically treated boiler water. Refill the boiler completely with clean, hot water. Drain
the boiler again.
7.
Remove all handhole and manway covers from the boiler pressure vessel. Inspect the
waterside of the boiler for cleanliness. Reinstall the handhole and manway covers using
new replacement gaskets.
Section 3:
8. Reinstall the boiler safety valves on the boiler, including the discharge piping. Fill the boiler
with clean, chemically treated water to its normal operating level. The boiler is now ready for
initial start-up or to be placed into service.
WARNING:
HANDHOLE, MANWAY AND SMOKEBOX DOOR GASKETS MUST BE CHECKED FOR
LEAKAGE FOLLOWING INITIAL OPERATION OF THE BOILER. THESE GASKETS MAY
BEGIN TO LEAK DUE TO TEMPERATURE AND PRESSURE CHANGES AND EXPANSION
OR CONTRACTION.
Suspended Matter
Oil and Grease
Boiler Water
pH
Alkalinity (m)
T.D.S.
Phosphate Residual
Dissolved Oxygen
Suspended Matter
Silica
10.5-11.5
700 ppm (max.)
Boilers sized 20,000 pph or less 3500 ppm (max.). Boiler
sized larger than 20,000 pph 2500 ppm (max.)
50 ppm as PO4 (min.)
Zero
If sodium sulfite is used for oxygen scavenging, maintain 2550 ppm as Na2SO3.
50 ppm (max.)
125 ppm (max.)
This information is supplied as general guidance only and does not absolve the boiler
owner from the responsibility of determining and maintaining water standards appropriate
to the specific local water chemistry and specific boiler use.
Section 4: Maintenance
A. General
A good maintenance program is essential to the lasting operation of your Johnston Boiler. Properly
maintaining the boiler will reduce unnecessary downtime, lower repair costs, and increase safety.
All electronic and mechanical systems require periodic maintenance. Automatic features do not relieve
the operator from maintenance duties.
A chart of added energy costs due to scale deposits can be found in Section 5 item D of this manual.
B. Part-Specific Maintenance
Most of the components and systems of your Johnston Boiler require little maintenance other than regular
inspection. Cleanliness is essential to the inspection of the boiler. Keep the exterior free of dust. Keep
the controls clean.
See individual component manuals for more information on specific component maintenance issues.
C. Maintenance Schedule
Johnston Boiler Company recommends the following maintenance schedule for the upkeep of your
Johnston Boiler. Any omission from this schedule could cause the Warranty to be voided. Only qualified
and experienced boiler, burner, and control personnel should attempt any maintenance and/or repair on
any boiler/burner. Be sure you have read and understand this entire manual before attempting
maintenance or repair.
Daily:
The following maintenance tasks should be performed daily by the operator:
1. Check the boiler for a proper water level. Low water can lead to over heating of the boiler heating
surfaces. High water can lead to carryover on steam boilers. Both conditions are dangerous.
2. Test the water cut-off controls. Also refer to item 7.
3. Check the operation of the boiler feedwater pump, control, and valve (regulator).
4. Check the boiler feedwater pump for proper operating pressures and temperatures.
5. Check over the boiler for proper operating pressures and temperatures.
6. Check to make sure that an adequate air supply into the boiler room is being maintained.
7. Blowdown the boiler. The water column and gauge glass (steam boilers only) and low water cutoff control(s) drain valves must be operated daily. A 15 second blowdown is adequate. The
boiler bottom blowdown valves should be operated daily. First open the quick opening valve
(closest to the boiler). Then open and close the slow opening valve. The length of time it takes
to do so represents the normal length of time for a boiler blowdown. Now close the quick opening
valve. Crack open and close the slow opening valve. This will relieve any pressure trapped
between the valves.
8. Check for leaks. Any leaks in the piping, fittings, controls, handhole, or manway openings should
be attended to promptly. All pressures and temperatures should be taken off the boiler and the
boiler drained down, isolated and locked out before any attempt to repair a waterside leak is
made. When replacing a gasket, sealing surfaces must be properly cleaned and prepared.
9. Check the condition of the boiler water for proper chemical treatment.
10. Maintain a clean, orderly, and safe boiler room.
Weekly:
The following maintenance tasks should be performed weekly by the operator:
1. If installed, check the boiler outlet flue gas damper for proper and smooth operation. Check the
linkage joints, arms, and rods for tightness.
2. Check the peepsite and sight port(s) for cracks in the lenses.
Section 4:
Monthly:
The following maintenance tasks should be performed monthly by the operator:
1. Check operation of the surface or continuous blowoff valve.
Annually:
The following maintenance tasks should be performed annually by the operator:
1. Check gauges and thermometers for proper calibration.
2. Open, clean (flush) and inspect the boiler waterside, including all water level controls, piping and
fittings.
3. Open, clean and inspect the boiler fireside. Inspect the condition of the boiler insulation, including
any refractory if present. Patch, replace or repair as necessary.
4. Check the condition of the fireside gasketing. Check for hardness and/or cracking. Replace
fireside gasketing as needed, but not less than every three years.
5. Replace waterside gasketing no less than once a year. Handhole and manway gaskets may be
required to be replaced more frequently. Handhole and Manhole gaskets should be checked for
condition (outside appearance) quarterly.
7. Lubricate studs and nuts and fluebox door hinges.
3. Dry Method
When it is known that the boiler will be laid up for an extended period of time, the dry method is used. It
is also used when an idle boiler filled with water is exposed to the possibility of freezing temperatures.
Section 4:
The operating boiler should be blown down, as would normally be done, just prior to lay-up. The boiler
must then be shut down, secured (valved off) and cooled. Once the boiler is cool, it must be vented and
completely drained. All handhole and manway covers must be removed. The waterside of the boiler
should then be flushed completely clean. Power washing is recommended. The waterside of the boiler
should then be allowed to completely dry.
Utilizing the handhole and manway access openings, using desiccant (or equal) in cloth bags, with
retrieving lines attached to the bags, place a sufficient number of the bags throughout the boiler pressure
vessel. Sixteen pounds of desiccant is required for every thousand gallons of boiler water capacity
(flooded). Leave the retrieving lines that are attached to the bags in the area of the handhole and
manway openings. Reinstall all handhole and manway covers. The old gaskets may be reused if in good
condition. Close the boiler vent. No greater than a 50% humidity level is to be maintained in the
waterside of the boiler, during that period the boiler will be laid-up.
When the boiler is required to be placed back in service, all desiccants must be removed from the boiler
waterside. New replacement handhole and manway gaskets must also be installed. The boiler must
then be filled with clean and chemically treated boiler water.
Depending on duration of lay-up, one might consider applying desiccant to the fireside as well.
Apply 1.2 oz/cu ft. of space.
Section 5: Engineering
A. Glossary of Terms
Absolute
Pressure
Alkalinity
Ambient
Temperature
Ampere
Anion
Area
ASME Code
Atmospheric
Pressure
Atomization
Atomize
Boiler
Boiler
Capacity
Boiler
Horsepower
Boiler
Shutdown
A
sequence
of
operation
completed when taking a boiler
off line.
Boiling Point
Temperature at which
changes into steam.
Bottom
Blowdown
Breeching
British
Thermal Unit
By-Pass Line
water
Calibrate
Carryover
Cavitation
Celsius
(Centigrade)
Continuous
Blowdown
Convection
Cracking
Open
Cross T
Cut-In
Pressure
Automatic
pressure
control
setting at which the boiler turns
on.
Cut-Out
Pressure
Automatic
pressure
control
setting at which the boiler turns
off.
Centrifugal
Force
Check Valve
Combustible
Material
Combustion
Complete
Combustion
Compound
Gauge
Condensate
Condense
Conduction
Dealkalizer
Differential
Pressure
Difference
between
two
pressures at different points.
Differential
Setting
Dissolved
Solids
Draft
Economizer
Flash Steam
Element
Foaming
Enthalpy
Erosion
Excess Air
Factor of
Evaporation
Force
Fahrenheit
Forced Draft
Furnace
Volume
Gate Valve
Gauge Glass
Gauge
Pressure
Gas Analyzer
Gas Leak
Detector
Gases of
Combustion
Gases
produced
combustion process.
Globe Valve
Gravity
Feedwater
Feedwater
Treatment
Fire Point
Firetube
Boiler
Has
heat
and
gases
of
combustion passing through the
furnace
and
boiler
tubes
surrounded by water.
Firing Rate
Flash Point
by
the
Handhole
Header
Heat
Exchanger
Heating
Surface
Heat
Recovery
System
Hot Water
Boiler
Hydrostatic
Pressure
Inches of
Mercury
Incomplete
Combustion
Infrared
Latent Heat
Laying Up
Low Water
Fuel Cutoff
Main Steam
Stop Valve
Maximum
Allowable
Working
Pressure
MOD Motor
Modulating
Pressure
Control
Pneumatic
System
Pounds of
Steam per
hour
NonCondensable
Gas
Popping
Pressure
Non-Return
Valve
Post-Purge
Pour Point
Normal
Operating
Water Level
Pre-Purge
Overfiring
Pressure
Pressure
Reducing
Station
Primary Air
Forced air
burner..
Priming
Process
Steam
Products of
Combustion
Natural Draft
Package
Boiler
Parallel
Positioning
Control
System
Passes
supplied
to
the
Perfect
Combustion
Programmer
PH
Proving Pilot
Pounds Per
Square Inch
Purge Period
Phosphates
Power
Quality of
Steam
Smoke
Density
Rate of
Combustion
Sodium
Zeolite Water
Softener
Raw Water
Untreated water.
Solid State
Reseat
Pressure
Soot
Ringlemann
Chart
Spalling
Safety Valve
Specific
Gravity
Spontaneous
Combustion
Occurs
when
combustible
materials self-ignite.
Stack
Safety Valve
Capacity
Volume to discharge.
Sample
Cooler
Saturated
Steam
Scale
Static Head
Pressure
Scotch
Marine Boiler
Steam
Secondary
Air
Steam Boiler
Sediment
Steambound
Steam Space
Steam Trap
Sludge
Sulfur
Superheated
Steam
Surface
Tension
Tensile
Stress
Therm
100,000 BTU
Thermal
Efficiency
Thermal
Shock
Total Force
Total Heat
Turbulence
Ultraviolet
Vacuum
Vacuum
Breaker
Vacuum
Gauge
Gauge
used
to
measure
pressures below atmospheric
pressure.
Valve
Vapor
Vertical
Firetube
Boiler
Viscosity
Waste Heat
Recovery
Boiler
Wet-Lay-Up
Working
Pressure
Section 5:
B. Boiler Formulas
Boiler Horse Power (HP):
BHP = (Lb/hr) * FE / 34.5
where Lb/hr is pounds of steam per hour
and FE is the factor of evaporation.
Steam:
Temperature Conversions:
F to C
C = (F 32) / 1.8
S=HP * 34.5 * t
where HP is boiler horsepower and t is
time (h).
C to F
F = (1.8 * C) + 32
Total Force (lb)
TF = P*A
where P is pressure (psi) and A is the
area of valve disc exposed to steam (sq.
in.)
Water Column (in)
WC = P / 0.03061
where P is pressure (psi).
C. Combustion
Flue gas analysis:
Horsepower (HP):
HP=(d * t) / (t * 33000)
where d is distance, F is force, and t is
time.
Indicates complete
combustion
Indicates incomplete
combustion
Indicates the presence
of excess air
A product of high
temperature combustion
Material that burns when
exposed to oxygen and
heat
Section 5:
Johnston Boiler Company recommends a
maximum #2 Smokespot (Ringelmann
Chart) in its oil fired burner.
Air Properties:
For a burner originally adjusted to 15% air,
changes in combustion air temperature
and barometric pressure cause the
following in excess air:
Air
Temperature
Barometric
Pressure
(In. HG)
Resulting
Excess Air %*
40
29
25.5
60
29
20.2
80
29
15.0
100
29
9.6
120
29
1.1
80
27
7.0
80
28
11.0
80
29
15.0
80
30
19.0
40
31
34.5
60
30
25.0
80
29
15.0
100
28
5.0
120
27
-5.5
* Expressed as a percent of the Stoichiometric air
required.
D. Energy Loss from Scale Deposits
ENERGY LOSS
FROM SCALE DEPOSITS IN BOILERS
SCALE THICKNESS
(INCHES)
1/32
8.50
1/25
9.30
1/20
11.10
1/16
12.40
1/8
25.00
1/4
40.00
3/8
55.00
1/2
70.00